Description:TECHNICAL FIELD
[0001] The present disclosure relates generally to the field of orthopaedic implants; and more specifically, to an artificial femoral component of a knee prosthesis and a method of manufacturing the artificial femoral component.
BACKGROUND
[0002] Typically, knee replacement prostheses include a femoral component that articulates with a tibial component. The choice of material for such prostheses has significance for their long-term success. Historically, prostheses have been manufactured from various materials, with titanium alloys being among the commonly used options. Titanium and its alloys, particularly Ti-6Al-4V, possess excellent biocompatibility and mechanical properties that make them popular for various biomedical implants. These materials offer favourable strength-to-weight ratios and have demonstrated good compatibility with human tissues. However, despite these advantages, titanium alloys exhibit certain limitations in knee prosthesis applications, especially for the femoral components. Specifically, these alloys demonstrate poor wear resistance, which is a major concern for joint replacement components like femoral components that experience significant articulation forces. Due to poor wear resistance of titanium alloys, the femoral components made of titanium alloys may lead to higher wear and tear of articulating surface of polyethylene liner which can further lead to aseptic loosening over time due to polyethylene wear particles. Furthermore, traditional knee prostheses often face challenges related to osseointegration and long-term fixation. The interface between the implant and bone is vital for implant stability and longevity. The inadequate osseointegration can lead to aseptic loosening, one of the primary causes of implant failure. While titanium generally demonstrates good osseointegration properties, the surface structure and treatment significantly impact the effectiveness of bone attachment. Additionally, infection at the implant site remains a serious complication that can lead to septic loosening and implant failure. Traditional materials and manufacturing methods often lack inherent antimicrobial properties to address this concern. Thus, there exists a technical problem where conventional 3D printed or additive manufactured femoral components made of titanium alloys suffer from poor wear resistance, causing particle release that leads to inflammation, osteolysis, and premature implant failure despite titanium's otherwise favourable biocompatibility properties.
[0003] Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks associated with the conventional 3D printed or additive manufactured femoral components made out of titanium alloy.
SUMMARY
[0004] The present disclosure provides an artificial femoral component of a knee prosthesis and a method of manufacturing the femoral component. The present disclosure provides a solution to the existing problem where conventional 3D printed or additive manufactured femoral components made of titanium alloys suffer from poor wear resistance, causing particle release that leads to inflammation, osteolysis, and premature implant failure despite titanium's otherwise favourable biocompatibility properties. An aim of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in the prior art, and provide an improved artificial femoral component of a knee prosthesis that addresses the limitations of existing materials while ensuring effective osseointegration and providing antimicrobial properties to prevent aseptic loosening due to infection. Additionally, there is provided an improved method of manufacturing the artificial femoral component that can produce such prostheses (femoral components) with precisely controlled surface properties and structure.
[0005] The object of the present disclosure is achieved by the solutions provided in the enclosed independent claims. Advantageous implementations of the present disclosure are further defined in the dependent claims.
[0006] In one aspect, the present disclosure provides an artificial femoral component of a knee prosthesis, comprising a unitary body formed of cobalt-chromium alloy using Direct Metal Printing (DMP). The unitary body comprises an articulating surface configured to articulate with a tibial component of the knee prosthesis and a bone-interfacing surface comprising a lattice trabecular structure configured to interface with a prepared femoral bone, where the lattice trabecular structure having interconnected pores is formed as an integrated part of the unitary body using the DMP, and where the bone-interfacing surface comprises a Hydroxy Apatite (HA) coating layer applied to the lattice trabecular structure.
[0007] The disclosed artificial femoral component made of cobalt-chromium (CoCr) alloy using the DMP offers superior wear resistance, high strength, and excellent biocompatibility, making it ideal for knee prostheses. The disclosed artificial femoral component comprises a highly polished articulating surface, which minimizes friction and polyethylene wear, enhancing implant longevity. The bone-interfacing surface features the lattice trabecular structure, which is integral to the unitary body and is specifically engineered to enhance osseointegration with a prepared femoral bone, promoting stability and longevity of the femoral implant. The interconnected pores within the lattice structure facilitate biological integration by allowing for the infiltration of bone tissue, which is further enhanced by the application of HA coating layer. This HA coating mimics the mineral composition of natural bone, thereby fostering a conducive environment for bone growth and attachment. The synergy between the DMP technology, which enables precise control over the microstructure and porosity of the lattice structure, and the HA coating applied through a suitable coating technique, which promotes biological compatibility, results in a prosthesis that not only exhibits high wear resistance and antimicrobial properties but also significantly reduces the risk of septic loosening due to infection. This comprehensive approach addresses vital challenges in prosthetic design, ensuring that the femoral component not only meets mechanical demands but also supports biological integration, ultimately leading to improved patient outcomes.
[0008] It is to be appreciated that all the aforementioned implementation forms can be combined. All steps which are performed by the various entities described in the present application as well as the functionalities described to be performed by the various entities are intended to mean that the respective entity is adapted to or configured to perform the respective steps and functionalities. It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
[0009] Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative implementations construed in conjunction with the appended claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:

FIG. 1A illustrates a lateral view of an artificial femoral component of a knee prosthesis, in accordance with an embodiment of the present disclosure;
FIG. 1B illustrates an interior view of an artificial femoral component of a knee prosthesis, in accordance with an embodiment of the present disclosure;
FIG. 1C illustrates an interior view of an artificial femoral component of a knee prosthesis, in accordance with another embodiment of the present disclosure;
FIG. 1D illustrates a lateral view of an artificial femoral component of a knee prosthesis, in accordance with another embodiment of the present disclosure; and
FIG. 2 is a flowchart of a method of manufacturing an artificial femoral component of a knee prosthesis, in accordance with an embodiment of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION OF EMBODIMENTS
[0011] The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
[0012] FIG. 1A illustrates a lateral view of an artificial femoral component of a knee prosthesis, in accordance with an embodiment of the present disclosure. With reference to FIG. 1A, there is shown a lateral view 100A of an artificial femoral component 102 of a knee prosthesis. The artificial femoral component 102 comprises a unitary body comprising an articulating surface 104 and a bone-interfacing surface with a lattice structure (not visible in FIG. 1A). The artificial femoral component 102 is represented by a dashed box, which is used for illustration purpose only.
[0013] The artificial femoral component 102 of the knee prosthesis is an anatomically designed metal implant that replaces the worn articular surface of distal femur. The artificial femoral component 102 is made from cobalt-chromium (CoCr) alloy and features a highly polished exterior surface with ceramic coating that articulates with a polyethylene tibial component, while its interior surface is engineered with a trabecular structure to promote osseointegration when used in cementless applications. The artificial femoral component 102 typically includes two curved condylar portions that reproduce the natural femoral condyles and a central patellar flange for articulation with a patella component of the knee prosthesis. The advanced manufacturing techniques, like Direct Metal Printing (DMP) allow for the creation of precisely controlled surface characteristics, including both the smooth articulating surface (often enhanced with ceramic coatings) and the porous bone-interfacing surface.
[0014] The articulating surface 104 is engineered to provide smooth, low-friction interaction with the polyethylene tibial insert during knee motion. The articulating surface 104 is meticulously polished and then enhanced with specialized ceramic coatings. These ceramic coatings significantly improve wear resistance and tribological characteristics, minimizing polyethylene wear particles that may otherwise lead to aseptic loosening over time. The anatomically curved design of the articulating surface 104, with its distinctive condylar portions, faithfully replicates natural knee kinematics through the full range of motion while distributing forces optimally across the joint.
[0015] FIG. 1B illustrates an interior view of an artificial femoral component of a knee prosthesis, in accordance with an embodiment of the present disclosure. FIG. 1B is described in conjunction with elements from FIG. 1A. With reference to FIG. 1B, there is shown an interior view 100B of the artificial femoral component 102 of the knee prosthesis. The interior view 100B represents a bone-interfacing surface comprising a lattice trabecular structure 106 of the artificial femoral component 102.
[0016] The bone-interfacing surface comprising the lattice trabecular structure 106 of the artificial femoral component 102 features a highly porous trabecular structure manufactured through Direct Metal Printing technology, creating interconnected pores that mimic natural cancellous bone architecture. The bone-interfacing surface with lattice trabecular structure 106 features a highly porous, interconnected network with irregular-shaped pores ranging from 200 to 800 microns, specifically engineered to mimic the architecture of natural cancellous bone. The lattice trabecular structure created through additive manufacturing using the DMP technology, ensures isotropic mechanical and physical properties while providing approximately 60% porosity throughout the bone-interfacing surface. The interconnected pores allow for vascular infiltration and osteoblast migration, facilitating robust bone ingrowth that creates a secure biological bond between the implant and the host bone. This advanced structural design, potentially enhanced with hydroxyapatite coating, represents a significant improvement over traditional implant surfaces, promoting faster osseointegration and long-term stability without requiring bone cement.
[0017] FIG. 1C illustrates an interior view of an artificial femoral component of a knee prosthesis, in accordance with another embodiment of the present disclosure. FIG. 1C is described in conjunction with elements from FIGs. 1A and 1B. With reference to FIG. 1C, there is shown an interior view 100C of the bone-interfacing surface with the lattice trabecular structure 106 of the artificial femoral component 102. The interior view 100C represents that the bone-interfacing surface with the lattice trabecular structure 106 comprises a first region 108A and a second region 108B having different thicknesses of the lattice trabecular structure. The lattice trabecular structure may also be referred to as Ossgrip. There is further shown a third region 108C without the lattice trabecular structure but having a rough surface.
[0018] FIG. 1D illustrates a lateral view of an artificial femoral component of a knee prosthesis, in accordance with another embodiment of the present disclosure. FIG. 1D is described in conjunction with elements from FIGs. 1A, 1B and 1C. With reference to FIG. 1D, there is shown a lateral view 100D of the articulating surface 104 of the artificial femoral component 102. The lateral view 100D represents a ceramic coating layer 110 over the articulating surface 104 of the artificial femoral component 102.
[0019] There is provided the artificial femoral component 102 of a knee prosthesis. The artificial femoral component 102 comprises a unitary body formed of cobalt-chromium alloy through additive manufacturing (3D printing) using the DMP technology. The artificial femoral component 102 of the knee prosthesis is designed as the unitary body formed of cobalt-chromium (CoCr) alloys, leveraging the material's superior mechanical properties for this demanding application. The cobalt-chromium (CoCr) alloys offer significant advantages for femoral components of knee prostheses compared to titanium alloys. Most notably, the cobalt-chromium alloys (specifically, cobalt-chromium-molybdenum (CoCrMo) alloy) possess superior wear resistance, a major factor in joint replacement longevity. Unlike titanium alloys that suffer from poor surface wear characteristics, the cobalt-chromium alloys can be highly polished to achieve exceptional surface smoothness, which significantly reduces friction and minimizes wear in metal-on-polyethylene bearing situations. This property is particularly vital for the articulating surfaces of knee implants that experience substantial mechanical stresses during normal movement.
[0020] Furthermore, the cobalt-chromium (CoCr) alloys demonstrate exceptional mechanical properties that make them ideal for heavily loaded joints, such as knee, hip, ankle, shoulder, and elbow implants. With hardness values approaching those of ceramic biomaterials, the cobalt-chromium alloys conforming to ASTM F75, ASTM F3213, and ISO 5832/4 standards provide excellent durability under impact and can withstand extreme forces before fracturing. This combination of surface wear resistance and mechanical strength directly translates to improved implant performance and longevity compared to titanium-based alternatives, particularly in the demanding biomechanical environment of the knee joint specially required for femoral component.
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[0021] The unitary body comprises the articulating surface 104 configured to articulate with a tibial component of the knee prosthesis. The articulating surface 104 is designed to interface with the tibial component of the knee prosthesis. The use of the DMP technology for creating the articulating surface 104 allows for precise control over the geometry and surface characteristics of the articulating surface 104, ensuring that the two condylar portions are accurately formed to match the anatomical requirements. The use of cobalt chromium alloy enhances the wear resistance of the articulating surface 104, addressing the limitations of titanium alloys. Additionally, the articulating surface 104 is coated with a ceramic layer to improve compatibility with the polyethylene insert, while the internal surface (i.e., the bone-interfacing surface with the lattice trabecular structure 106) is designed for osseointegration with the femoral bone. This combination of materials and manufacturing techniques ensures that the artificial femoral component 102 meets the mechanical and biological demands of the knee prosthesis.
[0022] In accordance with an embodiment, the articulating surface 104 comprises the ceramic coating layer 110 applied to the cobalt-chromium alloy through Physical Vapor Deposition (PVD). The articulating surface 104 is enhanced through an advanced ceramic coating layer (i.e., the ceramic coating layer 110) that is firmly bonded to the underlying cobalt-chromium alloy substrate using the PVD. Generally, the PVD is a vacuum-based coating process in which materials are vaporized and then condensed onto a substrate to form a thin, durable, and high-performance coating with enhanced wear resistance, corrosion protection, and biocompatibility. The articulating surface 104 is specifically coated with layers of specialized ceramic materials. The PVD coating process is selectively applied to the articulating surface 104 alone, ensuring that only the portion destined for contact with the polyethylene components receives this treatment. The ceramic coating layer 110 significantly enhances the tribological characteristics of the artificial femoral component 102, providing superior wear resistance while maintaining the exceptional mechanical properties of the underlying cobalt-chromium structure, ultimately extending the functional lifespan of the knee replacement system.
[0023] In accordance with an embodiment, the ceramic coating layer 110 comprises at least one material selected from a group comprising: Titanium Niobium Nitride (TiNbN), Titanium Aluminium Nitride (TiAlN), Titanium Nitride (TiN), and Zirconium Nitride (ZrN) or a combination thereof. The ceramic coating layer 110 applied to the articulating surface 104 of the artificial femoral component 102 is composed of at least one material selected from TiNbN, TiAlN, TiN, and ZrN, or a combination thereof, to enhance wear resistance, reduce friction, avoid any allergy that might cause due to metal ion release and improve overall implant longevity. These advanced ceramic coatings, applied through the PVD, form a highly durable and uniform layer that significantly minimizes the wear of the polyethylene insert, thereby reducing the risk of particle-induced osteolysis and implant loosening. The TiNbN and TiAlN coating provide superior hardness and oxidation resistance, while the TiN and ZrN coating contribute to low friction and excellent biocompatibility, ensuring smooth articulation with the tibial component. By incorporating one or more of these materials for the ceramic coating layer 110, the artificial femoral component 102 achieves enhanced mechanical properties, improved corrosion resistance, and long-term stability, making it a highly effective solution for knee prostheses subjected to high stress and repetitive motion.
[0024] In accordance with an embodiment, a thickness of the ceramic coating layer 110 is in a range of 0.5 to 7 micrometres (µm). The ceramic coating layer 110 applied to the articulating surface 104 of the artificial femoral component 102 has a thickness in the range of 0.5 to 7 microns, ensuring superior wear resistance while maintaining the structural integrity of the cobalt-chromium (CoCr) alloy substrate. The ceramic coating layer 110, deposited using the PVD, forms a highly uniform and adherent layer that enhances the hardness and scratch resistance of the artificial femoral component 102, reducing friction against the polyethylene insert and minimizing wear debris generation. The controlled thickness of the ceramic coating layer 110 ensures that the implant retains its biomechanical properties without compromising flexibility or introducing excessive stiffness that may lead to implant failure. Additionally, the ceramic coating layer 110 within the aforementioned thickness range, including TiNbN, TiAlN, TiN, and ZrN, provide a balance between durability and biocompatibility, ensuring long-term performance and stability of the knee prosthesis.
[0025] In accordance with an embodiment, the articulating surface 104 comprises an antimicrobial coating layer of Silver Chromium Nitride (CrNAg) applied to the cobalt-chromium alloy through the PVD. The articulating surface 104 of the artificial femoral component 102 includes the antimicrobial coating layer of CrNAg applied over the to the cobalt-chromium alloy through the PVD to enhance the implant’s resistance to infections and improve long-term biocompatibility. The antimicrobial coating layer of CrNAg, deposited using the PVD, provides a dual benefit of wear resistance and antimicrobial protection, reducing the risk of aseptic loosening caused by bacterial colonization. The Silver ions released from the CrNAg coating exhibit strong antibacterial properties, preventing biofilm formation and minimizing the likelihood of periprosthetic joint infections, a common complication in knee replacement surgeries. Furthermore, in an implementation scenario, the antimicrobial coating layer of CrNAg may be applied over the ceramic coating layer 110 of the articulating surface 104. The integration of the antimicrobial layer over the ceramic coating layer 110, such as TiNbN, TiAlN, TiN, or ZrN maintains the implant’s mechanical strength and tribological performance while offering additional protection against microbial contamination. The combination of wear-resistant ceramic coatings with the antimicrobial coating layer ensures improved implant longevity, reduced post-surgical complications, and enhanced overall patient outcomes.
[0026] The unitary body further comprises the bone-interfacing surface comprising the lattice trabecular structure 106 configured to interface with a prepared femoral bone, where the lattice trabecular structure having interconnected pores is formed as an integrated part of the unitary body using the DMP, and where the bone-interfacing surface comprises a Hydroxy Apatite (HA) coating layer applied to the lattice trabecular structure. The unitary body of the artificial femoral component 102 includes the bone-interfacing surface with the lattice trabecular structure 106, designed to integrate seamlessly with the prepared femoral bone. This highly porous structure, which mimics the natural architecture of cancellous bone, facilitates bone ingrowth and enhances osseointegration, ensuring a stable and long-lasting fixation without the requirement for bone cement. The bone-interfacing surface with the lattice trabecular structure 106 is created through the additive manufacturing (or 3D printing), such as the DMP technique, which allows for the precise fabrication of a random irregular trabecular network. Generally, the DMP is an advanced additive manufacturing technique that uses a laser to fuse metal powder layer by layer, creating a continuous and mechanically robust interface The lattice trabecular structure features interconnected pores, promoting a high porosity that mimics the natural architecture of bone. The orientation of the trabeculae is also random in three dimensions, enhancing the structural integrity of the artificial femoral component 102. Additionally, the bone-interfacing surface with the lattice trabecular structure 106 is designed to replicate the porous nature of bone, facilitating enhanced osseointegration. The incorporation of the HA coating, further supports bone growth by providing a bioactive surface for cellular attachment. The use of the DMP allows for precise control over porosity, optimizing the balance between mechanical strength and biological integration. By employing the DMP technology, the artificial femoral component 102 achieves superior structural integrity, long-term stability, and improved load distribution, ultimately enhancing the success and longevity of knee replacement procedures.
[0027] The DMP technology used for generating the unitary body (i.e., the articulating surface 104 and the bone-interfacing surface comprising the lattice trabecular structure 106 as a single component) of the artificial femoral component 102 enables the precise fabrication of complex, highly porous trabecular structures by laser-fusing metal powder layer by layer. This advanced additive manufacturing process allows for the creation of irregular, stochastic structures that mimic natural bone porosity, enhancing osseointegration and implant stability. The key process parameters include: the metal powder layer with a thickness in a range of 30-60 µm, ensuring fine control over structure formation, the metal powder particle size in a range of 15-45 µm or 15-53 µm, optimizing flowability and fusion quality, the laser beam diameter in a range of 70-80 µm, providing high precision in material consolidation, the laser power in a range of 250-300 watts, ensuring efficient fusion of the cobalt-chromium (CoCr) alloy, the scanning speed in a range of 600-1000 mm/sec, balancing accuracy and production speed, the scanning spacing in a range of 70-100 µm, maintaining uniformity in material deposition, the gas purity with 99.99% argon, preventing oxidation and ensuring material integrity, the Oxygen content <25 ppm during support printing and <10 ppm during actual part printing, minimizing contamination, and the process pressure of 150 mbar, optimizing fusion conditions. These parameters collectively contribute to the high structural integrity, precise porosity control, and superior mechanical performance of the artificial femoral component 102, making it an ideal solution for long-term knee implant stability.
[0028] Moreover, the DMP process offers several advantages over Selective Laser Melting (SLM), making it a superior choice for manufacturing orthopaedic implants, like the artificial femoral component 102. One key advantage is higher precision and surface quality, as the DMP utilizes finer powder layers (30-60 microns) and a controlled laser scanning strategy, resulting in smoother surfaces and more accurate geometries with minimal post-processing. Additionally, the DMP ensures superior metallurgical bonding, reducing porosity and defects while enhancing the mechanical integrity of the implant. Unlike SLM, which may introduce higher residual stresses, the DMP produces a more consistent and defect-free structure by using the oxygen content of <10ppm during actual part printing resulting in minimization of the contamination compared to the SLM process. Moreover, the advantage of maintaining the oxygen content less than 10ppm during 3D printing in DMP technology lies in enhancing the quality, purity, and performance of the printed parts. This further leads to avoid issues such as oxidation, material degradation, surface imperfections, and inconsistent mechanical properties. As a result, the parts produced are more reliable, durable, and suitable for high-precision, high-performance applications. Furthermore, the DMP is optimized for trabecular and lattice structures, enabling the creation of highly porous, interconnected architectures that promote superior bone ingrowth and osseointegration. While the SLM can also produce lattice structures, the DMP provides better control over porosity and structural randomness, which is required for long-term implant stability. These advantages make the DMP, a preferred choice for high-performance biomedical applications.
[0029] The bone-interfacing surface with the lattice trabecular structure 106 of the artificial femoral component 102 features the HA coating layer applied to the lattice trabecular structure to enhance osseointegration and long-term implant stability. The HA coating layer, a bioactive calcium phosphate material, closely resembles the mineral composition of natural bone, making it highly osteoconductive and promoting rapid bone cell adhesion and growth within the interconnected pores of the lattice trabecular structure. The HA coating layer provides an optimal surface for bone integration while maintaining the mechanical strength and porosity of the lattice structure, which mimics cancellous bone. Additionally, the HA coating layer improves adhesion strength (e.g., ≥15 Mega Pascal (MPa)) and features a controlled phase composition, ensuring enhanced biocompatibility and long-term fixation of the implant. By integrating the HA coating layer with the bone-interfacing surface with the lattice trabecular structure 106, the artificial femoral component 102 achieves superior stability, reduced risk of aseptic loosening, and improved clinical outcomes in knee replacement procedures.
[0030] In an implementation scenario, the controlled phase composition of the HA coating layer applied to the bone-interfacing surface with the lattice trabecular structure 106 of the artificial femoral component 102 ensures enhanced bioactivity and osseointegration. The phase composition may comprise the Hydroxyapatite ≥ 50 w% which ensures high osteoconductivity, promoting strong bone attachment and integration. The phase composition may also comprise Alpha-Tricalcium Phosphate (α-TCP), Beta-Tricalcium Phosphate (β-TCP) and Tetra-calcium Phosphate (TTCP) ≤ 30 w%, these calcium phosphate phases enhance resorption and bone remodelling, facilitating natural bone regeneration. The phase composition may also comprise Calcium Oxide (CaO) ≤ 5 w% which improves the stability and adhesion of the HA coating layer while maintaining biocompatibility. This phase composition provides a balanced mix of stability and bio-resorbability, ensuring long-term fixation and enhanced bone ingrowth for improved knee implant performance.
[0031] The HA coating layer applied over the bone-interfacing surface with the lattice trabecular structure 106 of the artificial femoral component 102 is designed with a porosity of, for example, 60%, ensuring enhanced bone ingrowth by facilitating cell migration, vascularization, and nutrient exchange. This high porosity mimics the natural structure of cancellous bone, promoting faster and more secure osseointegration. Additionally, the Calcium/Phosphate (Ca/P) ratio of, for example, 1.1 ± 0.1 is carefully controlled to enhance the coating’s bioactivity and stability. The mentioned ratio closely resembles the mineral composition of natural bone, ensuring excellent biocompatibility, bone bonding, and long-term fixation of the implant. These properties contribute to improved implant longevity and reduced risk of aseptic loosening.
[0032] In accordance with an embodiment, a thickness of the HA coating layer is in a range of 10 to 30 micrometres (µm). The HA coating layer applied over the bone-interfacing surface with the lattice trabecular structure 106 of the artificial femoral component 102 has a thickness in the range of 10 to 30 µm, ensuring enhanced osteoconductivity while maintaining structural integrity. This controlled coating thickness provides a bioactive surface that enhances bone cell adhesion and promotes rapid osseointegration within the bone-interfacing surface with lattice trabecular structure 106. A thickness within this range ensures sufficient coverage to stimulate bone growth while preventing delamination or excessive brittleness, which may compromise implant stability. Additionally, the HA coating layer, with an adhesion strength of ≥15 MPa, effectively bonds to the lattice trabecular structure, facilitating the long-term fixation and reducing the risk of implant loosening. By maintaining a precise coating thickness of the HA coating layer, the artificial femoral component 102 achieves an ideal balance between mechanical durability and biological integration, ultimately improving the success and longevity of knee replacement implants.
[0033] In accordance with an embodiment, the interconnected pores of the lattice trabecular structure are of random irregular shapes having dimensions in a range of 200 to 800 µm. The interconnected pores of the lattice trabecular structure are designed with random irregular shapes, having dimensions ranging from 200 to 800 µm (or microns), to closely mimic the natural architecture of cancellous bone and enhance osseointegration. This irregular porosity allows for improved bone cell migration, attachment, and vascularization, promoting faster and more secure bone ingrowth into the implant. The variation in pore size ensures a balance between mechanical strength and biological integration, where smaller pores facilitate cell adhesion while larger pores support nutrient exchange and bone remodelling. The bone-interfacing surface with the lattice trabecular structure 106, formed as the integrated part of the unitary body through the DMP process, creates a continuous and mechanically robust interface. By replicating the natural bone microstructure, the lattice trabecular design significantly improves implant stability, reduces stress shielding, and enhances long-term fixation, ultimately leading to better clinical outcomes in knee replacement procedures.
[0034] In accordance with an embodiment, the bone-interfacing surface with the lattice trabecular structure 106 comprises the first region 108A having a thickness of the lattice trabecular structure in a range of 0.6 millimetres (mm) to 0.85 mm, and the second region 108B having a thickness of the lattice trabecular structure in a range of 1.1 mm to 1.35 mm to accommodate varying loads and stress distributions across the artificial femoral component 102. As shown in FIG. 1C, the bone-interfacing surface with the lattice trabecular structure 106 comprises the first region 108A having the thickness of the lattice trabecular structure in the range of 0.6 mm to 0.85 mm, and the second region 108B having the thickness of the lattice trabecular structure in the range of 1.1 mm to 1.35 mm. Each of the first region 108A and the second region 108B is designed with specific thicknesses of the lattice trabecular structure to optimize load distribution. The first region 108A, with the thickness of the lattice trabecular structure ranging from 0.6 mm to 0.85 mm, is engineered to provide flexibility and adaptability to lower stress areas, allowing for natural bone integration. In contrast, the second region 108B, with the thickness of the lattice trabecular structure between 1.1 mm and 1.35 mm, is structured to withstand higher loads, ensuring stability and support in areas subjected to greater stress. This dual-thickness approach utilizes advanced material properties to enhance the mechanical performance of the component. The lattice design further promotes osseointegration by mimicking the natural trabecular bone structure, facilitating biological responses that enhance stability and longevity. These optimized thickness values of the lattice trabecular structure ensures that the artificial femoral component 102 achieves both biomechanical stability and long-term clinical success in knee replacement procedures.
[0035] In accordance with an embodiment, the lattice trabecular structure comprises a lattice pattern selected from a group comprising: a Voronoi pattern, a hexagonal pattern, a cubic pattern, a gyroid pattern, and a diamond pattern. The bone-interfacing surface with the lattice trabecular structure 106 is designed with a lattice pattern selected from the group comprising the Voronoi pattern, the hexagonal pattern, the cubic pattern, the gyroid pattern, and the diamond pattern, each offering distinct biomechanical and osseointegration advantages. These patterns are engineered to replicate the natural porosity of cancellous bone, optimizing load distribution while promoting bone cell migration and vascularization. The Voronoi pattern provides a randomized, biologically inspired structure that enhances stress distribution, while the hexagonal and cubic patterns offer uniformity and mechanical stability. The gyroid pattern features a continuous, non-self-intersecting surface ideal for balancing strength and permeability, whereas the diamond pattern ensures high porosity and structural integrity. These lattice designs, manufactured using the DMP, ensures durability and long-term fixation of the artificial femoral component 102. The selection of an appropriate lattice pattern allows customization of the implant’s mechanical properties, improving osseointegration and reducing the risk of stress shielding, ultimately enhancing the success of knee replacement procedures.
[0036] In an implementation scenario, the bone-interfacing surface with the lattice trabecular structure 106 (or the Ossgrip), based on a Voronoi-type design, is engineered to enhance osseointegration and mechanical stability in the artificial femoral component 102. This highly porous structure mimics the natural architecture of cancellous bone, promoting bone ingrowth and ensuring long-term fixation. The key features of the lattice trabecular structure may include, the lattice thickness of 1.1 to 1.35 mm in the second region 108B and 0.6 to 0.85 mm in the first region 108A, providing structural adaptability, the strut thickness of 0.3 to 0.35 mm, ensuring an optimal balance between mechanical strength and porosity, the porosity in a range of 50% to 65%, allowing for effective bone cell migration and vascularization, the mean pore size of 0.5 mm, facilitating bone ingrowth and nutrient exchange, the point spacing of 0.75 mm to 0.85mm for both 1.1 to 1.35 mm and 0.6 to 0.85 mm lattice thicknesses, ensuring uniform distribution, the random seed points as variable, creating a stochastic, biologically inspired structure for better load distribution, enhancing biological fixation while maintaining lightweight properties. This DMP-manufactured Voronoi lattice ensures an optimal combination of mechanical performance, bone integration, and long-term stability, making it an ideal feature of the femoral component for knee prostheses.
[0037] In accordance with embodiment, the bone-interfacing surface comprises the lattice trabecular structure in the first region 108A and the second region 108B and a rough surface without the lattice trabecular structure in a third region 108C, wherein each of the first region 108A, the second region 108B and the third region 108C comprises the HA coating layer. As shown in FIG. 1C, the third region 108C having the rough surface without the lattice trabecular structure. Although, the third region 108C has the HA coating layer.
[0038] Moreover, the bone-interfacing surface with the lattice trabecular structure 106 of the artificial femoral component 102 may also have a rough surface (i.e., the third region 108C), which can be designed using a cellular noise deboss pattern to enhance bone integration and implant stability by improving surface roughness for better osseointegration. The key parameters of the rough surface design may include, frequency: 3500, ensuring a fine yet structured surface texture for optimal bone attachment, depth factor: 0.6, providing sufficient surface roughness without compromising structural integrity, random seed: variable, allowing for a stochastic, natural bone-like texture, distance metric: Euclidean, ensuring uniform spacing and natural distribution of surface features and return type: Distance2Mul, optimizing the depth and pattern of surface roughness. This controlled rough surface modification, integrated through the DMP, enhances the biological fixation of the implant by promoting bone cell attachment and ingrowth, ultimately improving long-term implant stability and performance.
[0039] In accordance with an embodiment, the the lattice trabecular structure has porosity in a range of 50 to 65%. The porosity range of 50% to 65% is selected to balance the requirement for mechanical strength with the requirement for biological compatibility, ensuring that the artificial femoral component 102 can support bone integration over time.
[0040] Moreover, the artificial femoral component 102 may have different implementation scenarios. For example, in a first implementation scenario, the artificial femoral component 102 may have the articulating surface 104 and the bone-interfacing surface with the lattice trabecular structure 106 and the HA coating layer applied over the lattice trabecular structure. In a second implementation scenario, the artificial femoral component 102 may have the articulating surface 104 having the ceramic coating layer 110 of at least one material selected from the group comprising TiNbN, TiAlN, TiN, and ZrN or a combination thereof and the bone-interfacing surface with the lattice trabecular structure 106 and the HA coating layer applied over the lattice trabecular structure. In a third implementation scenario, the artificial femoral component 102 may have the articulating surface 104 having the antimicrobial coating layer of CrNAg and the bone-interfacing surface with the lattice trabecular structure 106 and the HA coating layer applied over the lattice trabecular structure. In a fourth implementation scenario, the artificial femoral component 102 may have the ceramic coating layer 110 as well as the antimicrobial coating layer of CrNAg and the bone-interfacing surface with the lattice trabecular structure 106 and the HA coating layer applied over the lattice trabecular structure.
[0041] Thus, the artificial femoral component 102 made of cobalt-chromium (CoCr) alloy using the DMP process offers several advantages that make the cobalt-chromium alloy an ideal material for knee prostheses, ensuring superior durability, wear resistance, and long-term implant stability. The cobalt-chromium (CoCr) alloy possesses excellent hardness and surface polish ability, allowing for an incredibly smooth articulating surface that minimizes wear when interacting with the polyethylene insert, thereby reducing debris generation and extending implant longevity. The high strength and fracture resistance property of the artificial femoral component 102 make it capable of withstanding extreme loads and repetitive mechanical stresses without compromising performance. Additionally, the artificial femoral component 102 benefits from an advanced ceramic coating layer, such as the TiN, or ZrN, or TiAlN, applied over the articulating surface 104 through the PVD technique, which further enhances wear resistance and reduces friction. To improve biocompatibility and combat implant-associated infections, the antimicrobial coating layer of CrNAg can be applied over the articulating surface 104 either in presence or absence of the ceramic coating layer 110, effectively reducing bacterial colonization and preventing aseptic loosening. The bone-interfacing surface with the lattice trabecular structure 106 of the artificial femoral component 102 features a highly porous structure, which mimics natural cancellous bone and promotes rapid osseointegration. The lattice trabecular structure, with pore sizes ranging from 200 to 800 microns, is coated with the HA coating layer (10-30 µm thick), further enhancing bone cell attachment and integration. The lattice trabecular structure is available in various patterns, such as the Voronoi, hexagonal, cubic, gyroid, and diamond, allowing for enhanced mechanical properties, improved load distribution, and reduced stress shielding. With its combination of high wear resistance, antimicrobial properties, and excellent osseointegration capability, the artificial femoral component 102 provides enhanced long-term stability, reduced risk of implant failure, and improved clinical outcomes for knee replacement patients.
[0042] FIG. 2 is a flowchart of a method of manufacturing an artificial femoral component of a knee prosthesis, in accordance with an embodiment of the present disclosure. FIG. 2 is described in conjunction with elements from FIGs. 1A, 1B, 1C and 1D. With reference to FIG. 2, there is shown a method 200 of manufacturing the artificial femoral component 102 of a knee prosthesis. The method 200 includes steps 202 to 206. The step 202 includes a sub-step 202A which further includes two sub-steps 202A1 and 202A2.
[0043] At step 202, the method 200 comprises forming a unitary body of a cobalt-chromium alloy using Direct Metal Printing (DMP). The method 200 involves forming a unitary body from cobalt-chromium (CoCr) alloy, a material known for its exceptional strength, wear resistance, and biocompatibility, making it ideal for knee prostheses. The cobalt-chromium (CoCr) alloy ensures that the artificial femoral component 102 can withstand high mechanical loads while maintaining a highly polished, smooth articulating surface that minimizes friction and wear against the polyethylene insert. Furthermore, the method 200 is based on utilization of the DMP technology for the unitary body, which involves the fusion of cobalt-chromium alloy powder using a laser beam as the energy source. This process allows for the creation of the unitary body with complex geometries and irregular structures.
[0044] At sub-step 202A1 of the sub-step 202A, the method 200 comprises consolidating successive layers of cobalt-chromium alloy powder using a laser beam to create an articulating surface configured to articulate with a tibial component of the knee prosthesis. The method 200 involves the use of the DMP technology, which employs the laser beam as the energy source to consolidate successive layers of cobalt-chromium alloy powder. This process allows for precise control over the melting and solidification of the metal powder, resulting in a dense and uniform structure. The cobalt-chromium alloy is selected for its superior mechanical properties, including high wear resistance and durability under load, making it suitable for heavily loaded joints. The articulating surface 104 of the artificial femoral component 102 is produced with a high degree of smoothness, which is required for minimizing wear in metal-on-polyethylene bearing situations. Additionally, the ability to achieve a polished surface enhances the articulating characteristics with the tibial component, ensuring improved performance during movement.
[0045] At step 204, the method 200 further comprises applying the ceramic coating layer 110 to the articulating surface 104 of the unitary body through PVD, where the articulating surface 104 is configured to articulate with a tibial component of the knee prosthesis. This ceramic-coated articulating surface enhances the durability of the artificial femoral component 102 and reduces polyethylene wear, optimizing its interaction with the tibial component of the knee prosthesis for improved long-term performance.
[0046] The ceramic coating layer 110 comprises at least one material selected from a group comprising TiNbN, TiAlN, TiN, and ZrN or a combination thereof. The thickness of the ceramic coating layer 110 is in a range of 0.5 to 7 µm. The method 200 further comprises applying an antimicrobial coating layer of Silver Chromium Nitride (CrNAg) either in the presence of the ceramic coating layer 110 (i.e., over the ceramic coating layer 110) or in the absence of the ceramic coating layer 110 (i.e., directly over the articulating surface 104 made of the cobalt-chromium alloy) through the PVD. The benefits of applying the antimicrobial coating layer of CrNAg either over the ceramic coating layer 110 or over the cobalt-chromium alloy are described in detail, for example, in FIGs. 1A, 1B, 1C and 1D.
[0047] At sub-step 202A2 of the sub-step 202A, the method 200 comprises consolidating successive layers of the cobalt-chromium alloy powder using the laser beam to create a bone-interfacing surface comprising a lattice trabecular structure configured to interface with a prepared femoral bone, where the lattice trabecular structure having interconnected pores is formed as an integrated part of the unitary body. The method 200 involves the use of the DMP technology for manufacturing the bone-interfacing surface with the lattice trabecular structure 106. The DMP process allows for precise control over the geometry and porosity of the lattice trabecular structure, ensuring enhanced integration with the prepared femoral bone. The lattice structure is designed to mimic the natural trabecular bone, promoting biological fixation and enhancing load distribution. Additionally, the bone-interfacing surface with the lattice trabecular structure 106 can be treated with bioactive coatings to further improve osseointegration.
[0048] At step 206, the method 200 further comprises applying a Hydroxy Apatite (HA) coating layer to the bone-interfacing surface comprising the lattice trabecular structure 106. The incorporation of the HA coating over the lattice trabecular structure enhances the implant's ability to integrate with bone, resulting from the increased surface area and favourable chemical properties of the HA coating. The thickness of the HA coating layer is in a range of 10 to 30 µm. The interconnected pores of the lattice trabecular structure are of random irregular shapes having dimensions in a range of 200 to 800 µm. Furthermore, the lattice trabecular structure comprises a lattice pattern selected from a group comprising: a Voronoi pattern, a hexagonal pattern, a cubic pattern, a gyroid pattern, and a diamond pattern, described in detail, for example, in FIGs. 1A, 1B, 1C and 1D. Moreover, the bone-interfacing surface with the lattice trabecular structure 106 comprises the first region 108A having a thickness of the lattice trabecular structure in a range of 0.6 mm to 0.85 mm, and the second region 108B having a thickness of the lattice trabecular structure in a range of 1.1 mm to 1.35 mm to accommodate varying loads and stress distributions across the artificial femoral component 102, as shown in FIG. 1C. The bone-interfacing surface comprises the lattice trabecular structure in the first region 108A and the second region 108B and a rough surface without the lattice trabecular structure in the third region 108C, wherein each of the first region 108A, the second region 108B and the third region 108C comprises the HA coating layer, described in detail, for example, in FIGs. 1A, 1B, 1C and 1D.
[0049] In accordance with an embodiment, consolidating the successive layers of the cobalt-chromium alloy powder comprises using the laser beam with a power in a range of 250 to 300 watts, a diameter in a range of 70-80 µm, a laser scanning speed in a range of 600-1000 mm/sec and scanning spacing in a range of 70-100 µm. The method 200 involves consolidating successive layers of the cobalt-chromium alloy powder by employing the laser beam with the power ranging from 250 to 300 watts. This power range is optimal for melting the metal powder, having the particle dimensions of in the range of 15-45 µm or 15-53 µm. The laser beam diameter of 70 to 80 µm ensures precise targeting of the powder layers, facilitating effective fusion. The controlled laser power enables the formation of a surface that can be polished to achieve high smoothness, reducing wear in metal-on-polyethylene bearing situations. Furthermore, the method 200 employs the laser scanning speed ranging from 600 to 1000 mm/sec to effectively fuse the cobalt-chromium alloy powder. This speed facilitates the precise melting of the metal powder layer, ensuring that the laser beam accurately targets and melts the powder particles. The stochastic structures created during this process allow for the formation of irregular shapes that are tailored to the specific requirements of the artificial femoral component 102. The method 200 employs the scanning spacing of 70 to 100 µm, which is optimized for the fusion of the cobalt-chromium alloy powder during the DMP process. This spacing is required as it aligns with the diameter of the laser beam, which ranges from 70 to 80 microns, ensuring effective energy transfer for melting the metal powder. The thickness of the metal powder layer, set between 30 to 60 microns, complements the scanning spacing, allowing for precise layer deposition. Additionally, the dimensions of the metal powder, which vary from 15 to 45 or 15 to 53 microns, facilitate the creation of interconnected pores with random irregular shapes, enhancing the structural integrity of the 3D printed femoral component.
[0050] In accordance with an embodiment, the cobalt-chromium alloy powder has particle dimensions in a range of 15-45 µm or 15-53 µm. The cobalt-chromium alloy powder is processed to achieve particle dimensions within the specified range of 15-45 microns or 15-53 microns, which is required for optimal layer thickness during manufacturing. The thickness of the metal powder layer is maintained between 30-60 microns, ensuring uniformity and consistency in the final product. The dimensions of the metal powder are vital as they influence the interaction with the laser beam, which has the diameter of 70 to 80 microns, allowing for effective melting and bonding of the particles.
[0051] In accordance with an embodiment, forming the unitary body of the cobalt-chromium alloy using DMP comprises oxygen content less than 10 parts per million (ppm) during actual part printing and less than 25ppm during support printing, a process pressure of 150 millibar (mbar) and a gas purity with 99.99% argon. The DMP technology facilitates the production of cobalt-chromium alloy components by utilizing the laser to fuse the metal powder. During the printing process, it is required to maintain the oxygen content of less than 10 ppm to prevent oxidation, which can adversely affect the mechanical properties of the alloy. The reduction of the oxygen content during part printing leads to improved mechanical properties and surface characteristics of the cobalt-chromium alloy, resulting in enhanced durability and reduced wear in joint replacement applications. Moreover, the method 200 employs a controlled environment during the support printing process, ensuring that the concentration of contaminants remains below 25 ppm. This is achieved by utilizing advanced filtration systems that purify the air and materials used in the 3D printing process. Maintaining the concentration of less than 25 ppm during support printing is required to ensure the integrity and performance of the 3D-printed implants (i.e., the artificial femoral component 102). This level of purity minimizes the risk of defects and enhances the overall quality of the surgical components. Moreover, the method 200 involves maintaining the process pressure of 150 mbar during the additive manufacturing process, specifically utilizing the DMP technology. The controlled process pressure enhances the quality of the metal powder consolidation, resulting in improved structural integrity and performance of the final component (i.e., the artificial femoral component 102). Additionally, the use of high-purity argon gas during the coating process minimizes contamination, leading to improved coating integrity and performance of the artificial femoral component 102.
[0052] In accordance with an embodiment, applying the HA coating layer to the bone-interfacing surface comprising the lattice trabecular structure 106 comprises using a suitable coating process selected from a group comprising: sol-gel dip, Electrophoretic Deposition (EPD), plasma spraying, magnetron sputtering, Ion Beam Assisted Deposition (IBAD), and Chemical Vapor Deposition (CVD). The term "sol-gel dip" refers to a technique involving the immersion of a substrate into a sol-gel solution, resulting in the formation of a thin film upon drying and subsequent heat treatment. The term "Electrophoretic Deposition (EPD)" refers to an electrochemical process in which charged particles are deposited onto a substrate under the influence of an electric field. The term "plasma spraying" refers to a thermal spray process that utilizes a plasma jet to melt and propel coating materials onto a substrate, forming a dense coating layer. The term "magnetron sputtering" refers to a physical vapor deposition technique that employs a magnetically enhanced plasma to eject material from a target onto a substrate. The term "Ion Beam Assisted Deposition (IBAD)" refers to a deposition method that combines the physical vapor deposition of materials with the simultaneous bombardment of the substrate by an ion beam to improve film quality. The term "Chemical Vapor Deposition (CVD)" refers to a process in which gaseous reactants undergo chemical reactions on a substrate surface to form a solid material layer. The appropriate selection of the coating process ensures robust adhesion and uniform coverage of the lattice trabecular structure with the HA coating layer, enhancing bioactivity and integration with the prepared femoral bone for improved long-term implant stability and functionality.
[0053] The steps 202 to 206 are only illustrative and other alternatives can also be provided where one or more steps are added, one or more steps are removed, or one or more steps are provided in a different sequence without departing from the scope of the claims herein.
[0054] Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural. The word "exemplary" is used herein to mean "serving as an example, instance or illustration". Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments and/or to exclude the incorporation of features from other embodiments. The word "optionally" is used herein to mean "is provided in some embodiments and not provided in other embodiments". It is appreciated that certain features of the present disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the present disclosure, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination or as suitable in any other described embodiment of the disclosure.
, Claims:We Claim:
1. An artificial femoral component (102) of a knee prosthesis, comprising:
a unitary body formed of cobalt-chromium alloy using Direct Metal Printing, DMP, the unitary body comprising:
an articulating surface (104) configured to articulate with a tibial component of the knee prosthesis; and
a bone-interfacing surface comprising a lattice trabecular structure (106) configured to interface with a prepared femoral bone, wherein the lattice trabecular structure having interconnected pores is formed as an integrated part of the unitary body using the DMP, and wherein the bone-interfacing surface comprises a Hydroxy Apatite (HA) coating layer applied to the lattice trabecular structure.

2. The artificial femoral component (102) as claimed in claim 1, wherein the articulating surface (104) comprises a ceramic coating layer (110) applied to the cobalt-chromium alloy through Physical Vapor Deposition, PVD.

3. The artificial femoral component (102) as claimed in claim 2, wherein the ceramic coating layer (110) comprises at least one material selected from a group comprising: Titanium Niobium Nitride (TiNbN), Titanium Aluminium Nitride (TiAlN), Titanium Nitride (TiN), and Zirconium Nitride (ZrN) or a combination thereof.

4. The artificial femoral component (102) as claimed in claim 2, wherein a thickness of the ceramic coating layer (110) is in a range of 0.5 to 7 micrometres, µm.

5. The artificial femoral component (102) as claimed in claim 1, wherein the articulating surface (104) comprises an antimicrobial coating layer of Silver Chromium Nitride (CrNAg) applied to the cobalt-chromium alloy through the PVD.

6. The artificial femoral component (102) as claimed in claim 1, wherein a thickness of the HA coating layer is in a range of 10 to 30 µm.

7. The artificial femoral component (102) as claimed in claim 1, wherein the interconnected pores of the lattice trabecular structure are of random irregular shapes having dimensions in a range of 200 to 800 µm.

8. The artificial femoral component (102) as claimed in claim 1, wherein the bone-interfacing surface with the lattice trabecular structure (106) comprises a first region (108A) having a thickness of the lattice trabecular structure in a range of 0.6 millimetres, mm, to 0.85 mm, and a second region (108B) having a thickness of the lattice trabecular structure in a range of 1.1 mm to 1.35 mm to accommodate varying loads and stress distributions across the artificial femoral component (102).

9. The artificial femoral component (102) as claimed in claim 1, wherein the bone-interfacing surface comprises the lattice trabecular structure in the first region (108A) and the second region (108B) and a rough surface without the lattice trabecular structure in a third region (108C), wherein each of the first region (108A), the second region (108B) and the third region (108C) comprises the HA coating layer.

10. The artificial femoral component (102) as claimed in claim 1, wherein the lattice trabecular structure comprises a lattice pattern selected from a group comprising: a Voronoi pattern, a hexagonal pattern, a cubic pattern, a gyroid pattern, and a diamond pattern.

11. The artificial femoral component (102) as claimed in claim 1, wherein the lattice trabecular structure has porosity in a range of 50 to 65%.

12. A method (200) of manufacturing an artificial femoral component (102) of a knee prosthesis, the method (200) comprising:

forming a unitary body of a cobalt-chromium alloy using Direct Metal Printing, DMP, wherein forming the unitary body comprises;
consolidating successive layers of cobalt-chromium alloy powder using a laser beam to create:
an articulating surface (104) configured to articulate with a tibial component of the knee prosthesis; and
a bone-interfacing surface comprising a lattice trabecular structure (106) configured to interface with a prepared femoral bone, wherein the lattice trabecular structure having interconnected pores is formed as an integrated part of the unitary body; and
applying a Hydroxy Apatite, HA coating layer to the bone-interfacing surface comprising the lattice trabecular structure (106).

13. The method (200) as claimed in claim 12, wherein consolidating the successive layers of the cobalt-chromium alloy powder comprises using the laser beam with a power in a range of 250 to 300 watts, a diameter in a range of 70-80 µm, a laser scanning speed in a range of 600-1000 mm/sec and a scanning spacing in a range of 70-100 µm.

14. The method (200) as claimed in claim 12, wherein the cobalt-chromium alloy powder has particle dimensions in a range of 15-45 µm or 15-53 µm.

15. The method (200) as claimed in claim 12, wherein forming the unitary body of the cobalt-chromium alloy using DMP comprises oxygen content less than 10 parts per million, ppm, during actual part printing and less than 25ppm during support printing, a process pressure of 150 millibar, mbar, and a gas purity with 99.99% argon.

16. The method (200) as claimed in claim 12, wherein applying the HA coating layer to the bone-interfacing surface comprising the lattice trabecular structure (106) comprises using a suitable coating process selected from a group comprising: sol-gel dip, Electrophoretic Deposition, EPD, plasma spraying, magnetron sputtering, Ion Beam Assisted Deposition, IBAD, and Chemical Vapor Deposition, CVD.